Gear selector

[dek]

Hello

I'm having an issue with my gear selector on my T5.

The issue is when in third and changing into fourth under acceleration, it would pop out of gear and make you look like a right dick.

I took off selector box and removed the selector arm,the holes at the end were enlarged and the pin was worn, so I ordered a new selector box.

This is where I thought my problem would be solved but it gets worse, put on new box and now the wee roller does not rest in the indents when it is neutral, first or fourth gear.

I've had it on and off even put my old one back on to see if I was doing it correctly, the roller went in to all the correct indentations still with the old box.

So I then stripped new arm and pin off and stuck them in my old selector box, still had my issue with roller not resting in indents when in gear.

Could the problem be the gears may be out of tolerance and require shimming because there was a lot of movement in the old selector arm.
Cheers

[dek]

Oh and it is the correct selector box

[adrian]

Sounds like the crusaform is worn out, might be wrong, but sounds like it

[adrian]

Have you checked cables and correctly tension

[dek]

Cruciform was replaced 270 miles ago.

Cables aren't connected, I was just checking it was going to select the gears before I connected them.
I've got the back wheel off the deck and turning the wheel and the batwing by hand.
Was going to stick it neutral and connect cables,but when it's in neutral the roller on the selector arm is sitting on top of a peak rather than in irs indentation.

[adrian]

Is the gear selector rod screwed right in ? Or damage to the end Only thing I can think of without seeing

[dek]

Tried screwing the selector rod in, it did turn but only very slightly, still no joy.

No damage to the end.

Looks like a strip down is on the cards then.

[adrian]

It is looking like an engine split 😒 but this is part of the reason we all love scooters 🛵🛵🛵

[L4NFF]

Just be sure you have replaced the gear selector box correctly. It can go on wrong as I have done this.

[dek]

I think I was doing it correctly.

My procedure was, selector arm in 4th position. Selector rod pulled all the way out.
Put the wee swivelling thingy in the end of the rod and box on to studs.
Then turned back wheel to pull on selector box.

[3narf]

Check the two halves of the quadrant 'sandwich' in the selector box are properly aligned - cheap ones from India are very badly put together with the indents not lining up with each other.

[dek]

I thought it might be the construction of the new selector box.
I put the selector arm and pin from the new box into my old box and tried with that still no joy, was still the same.
New and old arm are exactly the same length.
So I have stripped it down and the gap at then end of the transmission is 0.5mm, so I have ordered a couple of shims to bring it back into the tolerance.
I also read that the end of the selector rod should be tightened with a 17mm spanner, but the one I have is 13mm.
Are the older and newer selector rods both the same length as I cannot find any info about their dimensions.